​How To Fit Tail Lift Torsion Bar

Content Menu

● Tools and Preparation

● Step-by-Step Installation Process

>> Removing the Old Torsion Bar

>> Inspecting and Preparing Components

>> Installing the New Torsion Bar

>> Adjusting Preload and Ride Height

>> Final Checks and Alignment

● Common Installation Challenges

>> Stubborn Torsion Bar Engagement

>> Insufficient Preload Adjustment

● Maintenance Tips

● Frequently Asked Questions

● Citations:

Tail lift torsion bars are critical components for maintaining stability and controlled movement in vehicle lifting mechanisms. Proper installation ensures safe operation, reduces wear, and optimizes performance. This guide provides a comprehensive, step-by-step approach to fitting torsion bars, including tools, techniques, and troubleshooting tips.

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Tools and Preparation

Before starting, gather the following tools and materials:

- Half-inch wrenches (for adjusting bolts and locknuts)

- Rubber mallet (to avoid damaging components)

- Torsion bushing installation/reaming tool (for precise bushing alignment)

- Penetrating lubricant (to loosen seized components)

- Grease (for splines and bushings)

- Setup blocks (to measure ride height adjustments)

- Safety gear (gloves, eye protection)

Ensure the vehicle is on a level surface and the suspension is fully unloaded. Disconnect shocks or stabilizers to relieve tension from the torsion arms.

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Step-by-Step Installation Process

Removing the Old Torsion Bar

1. Loosen Adjuster Bolts: Back off the torsion bar adjuster bolts completely using a 19mm wrench. This releases tension from the suspension.

2. Detach Anchors: Remove the pinch bolts securing the torsion arms and anchors. Use penetrating oil if components are corroded.

3. Extract the Bar: Slide the torsion bar out of the front and rear splined sockets. If stuck, tap the bar gently with a rubber mallet or use a torsion bar removal tool.

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Inspecting and Preparing Components

- Check Bushings: Replace cracked or worn torsion bushings. Use the bushing tool to press old bushings out and install new ones.

- Clean Splines: Remove debris from splined sockets and torsion bar ends. Apply a thin layer of grease to ensure smooth engagement.

- Verify Directionality: Torsion bars are directional. Align manufacturer markings (e.g., stamped numbers) toward the torsion arm to maintain preload memory.

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Installing the New Torsion Bar

1. Align Splines: Match the torsion bar splines with the front and rear sockets. Rotate the bar slightly to find the optimal alignment.

2. Insert the Bar: Slide the bar into the rear socket first, then guide it through the front control arm. Use a rubber mallet to seat it fully.

3. Secure Anchors: Reattach the torsion arm and anchor, ensuring pinch bolts are tightened to specifications.

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Adjusting Preload and Ride Height

1. Set Preliminary Height: Use setup blocks under the axle to approximate the desired ride height. A 2" block typically lowers the vehicle, while a 1.25" block raises it.

2. Tighten Adjuster Bolts: Turn the adjuster bolts clockwise (right side) or counterclockwise (left side) to increase preload. Each full tooth rotation changes ride height by ~2.5mm.

3. Verify Free Play: Ensure 1/16"–1/8" of free movement in the torsion arm after adjustment.

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Final Checks and Alignment

- Test Suspension Travel: Jack the vehicle to confirm the torsion bar allows full droop without binding.

- Road Test: Drive the vehicle to settle components, then recheck ride height.

- Front-End Alignment: Adjust toe and camber settings, as torsion bar changes alter wheel geometry.

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Common Installation Challenges

Stubborn Torsion Bar Engagement

If the bar resists seating:

- Clean splines thoroughly and reapply grease.

- Rotate the bar incrementally to find optimal spline alignment.

- Avoid excessive force, which can damage splines.

Insufficient Preload Adjustment

For sagging torsion bars:

- Re-index the Anchors: Remove the anchor, rotate it 2–3 splines downward, and reinstall. This increases adjuster bolt thread availability.

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Maintenance Tips

- Lubricate Splines: Apply grease every 1–3 months to prevent corrosion.

- Inspect Bushings: Replace every 20,000–30,000 miles or if cracks appear.

- Monitor Ride Height: Measure hub-to-fender distance monthly to detect sagging.

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Frequently Asked Questions

1. How do I determine torsion bar directionality?

Look for manufacturer markings (e.g., stamped numbers) and align them toward the torsion arm.

2. Can I reuse old torsion bushings?

No-replace cracked or deformed bushings to prevent instability.

3. Why is my ride height uneven after adjustment?

Re-indexing one side more than the other or uneven adjuster bolt turns often causes this. Rebalance preload adjustments.

4. Do I need an alignment after installation?

Yes-torsion bar changes affect toe and camber.

5. What if the adjuster bolt threads are stripped?

Replace with an upgraded titanium bolt to prevent mushrooming and ensure durability.

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Citations:

[1] https://www.youtube.com/watch?v=1PiSl25it0c

[2] https://performatek.com/docs/dedion-torsion-bar-installation/

[3] https://forum.ih8mud.com/threads/for-those-with-torsion-bar-questions.491948/

[4] https://www.nissanpathfinders.net/forum/topic/17038-how-to-re-index-your-torsion-bars/

[5] https://www.forabodiesonly.com/mopar/threads/installing-torsion-bars-shouldnt-this-be-the-easy-part.405230/

[6] https://forum.ih8mud.com/threads/torsion-bar-fitting.1330534/

[7] https://www.youtube.com/watch?v=jZxg2RXq_6g

[8] https://fbg-instructions.sfo3.cdn.digitaloceanspaces.com/INST005.pdf

[9] https://sleeoffroad.com/wp-content/uploads/2018/09/PUB-ARB-Torsion-Bar-Adjustment.pdf

[10] https://www.youtube.com/watch?v=RFqfsSZdYfY

[11] https://www.tiktok.com/@lew.turn/video/7364842515469454624

[12] https://www.tommygate.com/media/944054/095056-repair-railgate-torsion-assist-spring-instructions-16-20-models.pdf

[13] https://www.directsuspensions.com.au/blogs/news/how-do-i-adjust-my-torsion-bars-to-get-more-lift

[14] https://fordtransit.org/forum/viewtopic.php?t=51300

[15] https://static.summitracing.com/global/images/instructions/ran-rs66350r5_revision_a.pdf

[16] https://www.silveradosierra.com/threads/tailgate-torsion-adjustment.212666/

[17] https://www.youtube.com/watch?v=AeNdyvOtxPk

[18] https://www.trailmanorowners.com/forum/showthread.php?p=104814&highlight=adjust+torsion

[19] https://hummer4x4offroad.com/forum/threads/torsion-bar-install-help.9839/

[20] https://forum.ih8mud.com/threads/tailgate-torsion-bar.109114/

[21] https://www.hiab-bel.com/images/del/docs/del_om_column-lifts.pdf

[22] https://www.reddit.com/r/MechanicAdvice/comments/10wtjrl/torsion_bar_questions/

[23] https://www.205gtidrivers.com/forums/topic/176828-torsion-bar-question/

[24] https://www.youtube.com/watch?v=XHvUekXWsjM

[25] https://www.silveradosierra.com/threads/torsion-bar-question.750132/

[26] https://board.moparts.org/ubbthreads/ubbthreads.php/topics/3193445/torsion-bar-install-question.html

[27] https://www.trucknetuk.com/t/tail-lift-fault/144874

[28] https://www.trucknetuk.com/t/tailift-info-needed/225290

[29] http://www.dhollandia.com/files/use-trad-en-2011-complete.pdf

[30] https://www.trailmanorowners.com/forum/showthread.php?t=20956

[31] http://www.hiab-bel.com/images/del/docs/del_im_column-lifts.pdf

[32] https://www.groundforce.com/files/instructions/leveling/3808-15223-rev-b.pdf

[33] https://www.etrailer.com/question-514849.html

[34] https://www.forabodiesonly.com/mopar/threads/torsion-bar-installation-position-question.384150/

[35] https://www.reddit.com/r/4x4/comments/1h2uop9/torsion_lift_problems/

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